LEAN and TPM Training & Certification

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1 LEAN and TPM Training & Certification Fall 2015/ Spring 2016 Lean Manager Certification Lead your organization s lean effort Lean Manager Certification for Services Fully accredited program designed for administration and service industry leaders Lean Tool Awareness Certificate Learn how and where to start your lean journey Manager of Maintenance Improvement Certificate Essential tools for managing and improving your maintenance process The TPM Experience The premier conference for driving operational performance through equipment and process reliability 3P: Production Preparation Process Become a game changer in your industry A Maintenance Miracle A 4-day Autonomous Maintenance Kaizen event TPM Manager Certification Program Implement TPM cost-effectively Learn the skills you need to succeed. Taught using a proven combination of classroom discussion, group activities, case studies, simulations and in some cases, handson application of the techniques, these courses provide solid, useful information you can immediately apply upon return to your facility. Elevate your skills. Improve organizational performance.

2 Lean Manager Certification Program The benchmark program for lean leaders since 2001 FALL 2015 / SPRING 2016 PROGRAM Columbus, OH FALL 2015 SPRING 2016 Week 1: September Week 2: October Week 3: November Week 4: December (Participants must attend all four weeks) Week 1: March Week 2: April Week 3: May Week 4: June (Participants must attend all four weeks) The Lean Manager Certification Program (LMAC) is a fully accredited program designed for middle and top-level executives who want to drive lean principles throughout their organizations. LMAC is an intensive and interactive program that teaches a carefully sequenced arrangement of lean concepts and techniques. Simulations, group exercises, problem-solving discussion sessions and shop floor application exercises transform theory into reality and education into implementation. With an instructional design similar to a Six-Sigma Black Belt Certification Program, the Lean Manager Certification Program will transform your career and the future prospects of your company. Week One PLAN Lean Manager Certification Curriculum Week Two PILOT Week Three DEPLOY Week Four INTEGRATE It has been the greatest course I have ever taken and I can t tell you how much I have learned. I knew a lot of the lean tools, but was not sure how or when to properly use them. I now also have so many new tools that I did not know about before this course. All the instructors have been great also! Productivity Inc. is loaded with talented people who are great teachers. I feel so much more valuable to my company. I will let them know that this is money well spent, and recommend we send more employees. Bob Wasilewski, Crew Supervisor, ATI Metals lead an organizational lean implementation perform an organizational assessment and establish baselines create a detailed deployment plan based on currentstate analysis act as principal change agent Participants will learn to: mentor and coach project leaders, area managers, and supervisors in specific tools and methods lead and direct site teams in plant-wide deployment of lean methodologies coach and mentor suppliers change agents to address critical quality and delivery problems LMAC is a Productivity Inc./Ohio State University Fisher College of Business Program. 2

3 LEAN MANAGER CERTIFICATION FOR SERVICES Service Winter 2016 Program Week 1: February 8-12, 2016 Week 2: March 7-11, 2016 Week 3: April 4-7, 2016 Columbus, Ohio (Participants must attend all three weeks) A three-week, fully accredited certification program specially designed to develop critical thinkers with the lean skills to: improve customer service and satisfaction reduce complexity and variability increase flexibility and speed improve productivity do more with current resources For... Insurance Banking Manufacturing support services Retail Healthcare administration Laboratories Government / Non-profit Human Resources Customer Service Marketing Accounting Research & Development Information Technology...and more The Lean Manager Certification for Services (LMAC Service) program shows administrative and service industry professionals how to achieve sustainable improvement in organizational performance and capability. Developed for senior and middle managers, LMAC Service is a highly competitive, interactive program that develops lean transformation managers, not simply project managers. Over three non-consecutive weeks, participants experience a series of learning modules focused on defining current state, deploying lean methods & developing a culture of improvement. Between training weeks, participants apply lean principles in processes at their own organizations and present their process and results to the class during subsequent training weeks. The combination of classroom discussion, group exercises, simulations, case studies, and hands-on application help you transform theory into reality and educational lessons into practical experiences. Participants who successfully complete the three-week training and mentoring program, demonstrate successful application in their own organization, and pass the certification exam are certified as Lean Managers and earn 12 CEUs. Gain the know-how, confidence, and problem-solving skills you need to drive waste from your processes and boost enterprise-wide performance. Become a Lean Manager! Lean Manager Certification Program for Administrators and Service Industry Professionals The Lean Manager Certification Program For Administration and Service Organizations is a Productivity Inc./Ohio State University Fisher College of Business Program. 3

4 Manager of Maintenance Improvement Certificate May 4-8, 2015 / April 25-29, 2016 Columbus, Ohio This program has been designed to provide you with nine essential tools for managing and improving your maintenance process. This fully accredited program teaches maintenance leaders the foundational tools needed to establish a world-class maintenance program. Chances are you already know you must do something to improve the reliability of your equipment, but you may not know exactly what to do or how to get started. This event will provide you with the answers and direction you need. Program Curriculum Monday Tuesday Wednesday Thursday Friday 8am-12pm The Zero Failure Principle Autonomous Maintenance Focused Improvement Maintenance Planning and Scheduling Setting Standards & Leading the Effort Establishing Key Maintenance Metrics and Measures The Waste Proof PM Process Machine Failure Analysis Managing the Storeroom & Spare Parts Very useful. It will change our approach to maintenance improvement. James Martin, Operations Improvement Manager, Allnex Lean Tool Awareness Certificate June 1-5, 2015 / November 16-20, 2015 Columbus, Ohio LTAC is a powerful training that will teach you how and where to start your Lean journey and help you build the skills and confidence to make a difference in your organization. Through a combination of classroom lecture, group activities and simulations, the Lean Tool Awareness Certificate Program focuses on providing an understanding of Lean processes, tools and philosophy so you can develop strategies for implementation at your site. Program Curriculum Monday Tuesday Wednesday Thursday Friday 8am-12pm The Visual Workplace Strategic Planning & Policy Deployment Standard Work Value Stream Management Total Productive Maintenance Achieving Quick Changeover Mistake-Proofing Team-Based Problem Solving I came with questions about the value. What could I get here that wasn t already in a book? I left with a great appreciation for the course and truly feel its value exceeds the cost of attending. Christopher Adams, Manufacturing Engineer, Gorbel, Inc. Productivity Inc. 375 Bridgeport Avenue, 3rd Floor, Shelton, CT or (203) Fax: (203)

5 3P First-of-its-kind event! Certification Production Preparation Process September 15-18, 2015 Hanover, PA An in-depth learning experience designed to teach the principles of 3P through a combination of classroom learning, simulation and an interactive tour and discussion with the R.H. Sheppard Co., Inc. 3P team. 3P Awareness Certificate 3P Practitioner Certificate White Belt Green Belt September 15, 2015 September 15-18, 2015 (session ends at 12 noon on Oct. 23) 3P Leader Certification Black Belt September 15-18, project dates TBD (session ends at 5pm on Oct. 23) Participate in the presentation, discussions and exercises that explain the 3P process, and meet with team members of a live 3P project. Participants will gain a solid conceptual understanding of the underlying theory of 3P, what wastes it eliminates and the processes used. You will leave with a macro-level grasp of 3P and what it can offer your enterprise. The Green Belt experience takes over where the White Belt discussion ends, providing participants with a deeper understanding of 3P. You will assume the role of a 3P team member and take part in a simulated 3P project. You will also visit a 3P project site, where you will see the process in action, tour the moonshine shop, talk to 3P team leaders and members and practice using some of the techniques taught during the training. You will leave with a deep understanding of the 3P process and be ready to support a 3P project in your enterprise. With the classroom learning, simulation, hands-on application exercise and opportunity to talk with the RH Sheppard 3P team, you now have a solid grasp of the 3P technique. In the remaining four hours, we will mentor you through the Seven Phases of 3P as we collaborate on building your project plan. You will leave the session with your project plan outline and a series of action items that will prepare the workplace for your first co-facilitated 3P project. This segment includes onsite cofacilitation of your project by an experienced Productivity Inc. 3P Consultant. At the conclusion of the Black Belt Certification, you will be well-qualified to lead future 3P projects on your own. About the host and their 3P Project The R. H. Sheppard name is recognized around the world as the standard of excellence in the design and manufacture of finely engineered products for the truck, bus, rail, construction, military and recreational vehicle industries. In 2012, top managers faced a key decision on capital investment. Rather than buy new equipment and clone their current manufacturing line, they decided to innovate. They would design a radically new process that would provide distinct competitive advantage. And with that, a 3P project was born! In just 16 weeks, a cross-functional team of production, maintenance, and engineering staff learned the 3P methodology, attacked the business problem, mocked up prototypes, ran trials, and made a final recommendation. That solution will allow R.H. Sheppard to manufacture with zero changeovers across 7 different part families, and 70-plus part numbers. The benefits: same-day delivery on any part, 30% capacity increase, at least 50% scrap reduction, reduced future costs for new equipment, and a strong internal capability to perform 3Ps and to implement advanced lean manufacturing techniques. 5

6 A Maintenance Miracle An Autonomous Maintenance Kaizen Event An intensive learning experience designed to teach the principles of Autonomous Maintenance through a combination of classroom learning and hands-on implementation. October 13-16, 2015 Columbus, Ohio Host Plant: Royal Building Products This Maintenance Miracle Kaizen Event is not an awareness course, but a hands-on training in a proven methodology for the successful implementation of an autonomous maintenance (AM) effort. In this 3½ day event, participants will gain exposure to Total Productive Maintenance, an eight pillar team-based approach to total equipment care, and learn about its vital role in a successful lean operation. Participants will deep-dive the seven step autonomous maintenance process that is the focus of the event. Then working in teams alongside associates from the host facility, participants will apply the methods learned as they work to transform current state to future state and increase equipment effectiveness and availability. At the end of the week, teams will report results to the group. At the conclusion of the event, you will understand the techniques and have the skills necessary to begin an autonomous maintenance effort in your own facility. What past participants had to say about A Maintenace Miracle: I think it was valuable to experience the real world by working with a plant that is early in its journey. If we had gone to a very mature TPM process, I would not have learned as much about the transformation that is required in the early stages. Victor Flint, Reliability Manager, Honeywell Knowledgeable, made sense, simple way to encompass a large complex process which breaks down into simple tasks and involvement from all. James Huff, Electrician, Cummins Great process to incorporate it involves teamwork, training, trouble-shooting and increases your bottom line when you can improve your processes. Chad Pennington, Shift Coordinator, Royal Building Products The event and host plant were great to perform and work with. The event flowed smoothly even with the amount of people and activities that were involved. I was impressed. Niles Frisbie, OPS Manager, Cummins I ve learned it is way cheaper to be proactive. Jeff Pleinis, Turning Center Lead, Goodrich About the Host Royal Building Products is a division of Axiall Corporation (formerly known as Georgia Gulf). The company manufactures and distributes leading materials for the home remodeling, building and municipal construction markets. For over 40 years, the company s commitment to quality, innovation and customer relationships has attracted the loyalty of a growing number of building professionals, homeowners, architects, engineers and distributors to its products which include vinyl siding, moldings & trim, window & patio doors, pipe fitting solutions and deck products. They have operations throughout North America. The Columbus, Ohio facility is comprised of two manufacturing plants and one warehouse. The Maintenance Miracle in-plant activities will take place in the 253,000 sq. ft. North Plant, home to over 200 employees. This is a non-union plant. For more information on Royal, visit their website at Productivity Inc. 375 Bridgeport Avenue, 3rd Floor, Shelton, CT or (203) Fax: (203)

7 MANAGER Certification Program... because your Lean Manager can t do it alone. TPM TPM CERTIFICATION PROGRAM TOTAL PRODUCTIVE MAIN T ENANCE SPRING 2016 PROGRAM (Participants must attend all four weeks) Columbus, OH Week 1: March 7-11 Week 2: April 4-8 Week 3: May 2-6 Week 4: June Working in concert with the Fisher College of Business at The Ohio State University, Productivity has combined more than 30 years of TPM experience with the resources of one of the top business schools in the country to create the Total Productive Maintenance Manager Certification Program. This certification program will teach you how to implement TPM cost effectively. The program is designed for individuals charged with systematically improving the maintenance process and overall equipment reliability. You ll see the benefits in reduced downtime, better yield, more reliable quality and increased product going out the door. The TPM Certification Program was one of the most rewarding accomplishments of our professional careers. It has given us the knowledge, skill, and inspiration needed to make positive changes in the way maintenance is carried out at Miba. -Troy Adams and Brent Graham, Production Support Engineers, Miba Bearings U.S. TPM Manager Certification Curriculum Week One March 7-11 Week Two April 4-8 Week Three May 2-6 Week Four June Participants will gain a solid knowledge of the eight pillars of TPM and will be able to: establish and customize an internal TPM Implementation strategy properly use machine performance data to identify and execute a Tactical Action Plan for success justify and implement a complete maintenance planning and scheduling process conduct and lead Autonomous Maintenance kaizen events design and perform site-specific TPM Auditing establish baseline data collection and understand the use of the OEE metric understand the need for and conduct breakdown analysis reviews organize and control spare parts use the principles of the Early Equipment Management process The TPM Manager Certification Program is a Productivity Inc./Ohio State University Fisher College of Business Program. Productivity Inc. 375 Bridgeport Avenue, 3rd Floor, Shelton, CT or (203) Fax: (203)

8 TPM Experience The premier event for driving operational performance through equipment and process reliability Keynote Presentations Case Studies Workshops Networking April 21-24, 2015 New Orleans, LA Excellent week of information. Highly recommended for teams starting their TPM journey. Drew Coville, TPM Supervisor, Exotic Metals Forming Company Join us for the only event dedicated to Total Productive Maintenance, the bedrock of Lean success. Watch our website for updates. Other Training and Consulting Services Available from Productivity On-Site Training Productivity offers a strong suite of Lean Tool workshops designed to remove roadblocks to Lean transformation. Hands-on, results driven sessions ranging from 1.5 to 4 days are delivered at your site. Whether you are looking for the basics to help you get started, or a more advanced tool to move your implementation to the next level, Productivity can help. We can also customize existing programs or design new ones tailored to address specific challenges facing your company. On-Site Consulting Working with small groups of employees from the boardroom to the manufacturing floor, our consultants will provide prescriptive solutions to your toughest implementation issues. Productivity s senior consultants are manufacturing process improvement professionals with real-world, hands-on experience implementing Lean and continuous improvement strategies in both the manufacturing and transactional environments. They are first generation Lean instructors having worked with the originators of process improvement. Productivity Strategic Innovation Following years of research and experimentation, Productivity has developed a major new suite of services on Strategic Innovation. Maintaining strategic focus on growing the top line, while improving the bottom line, is the significant challenge organizations must meet in order to sustain success. Productivity s Strategic Innovation System provides a comprehensive, flexible approach to building innovation capabilities. Using our scalable and configurable system, we can help you clarify existing value propositions, identify and create new ones, and cultivate a meaningful and sustainable strategy for top-line growth. To ensure that your improvement and growth strategies are working in tandem and aligned with your business strategy, get the process started by contacting us for more information and your own copy of our Innovation Primer Kit. For more information visit Productivity Healthcare Solutions Bringing Lean Techniques to the Healthcare Industry Productivity s Healthcare professionals have worked alongside providers, administrators, and payers to improve unique patient-care value streams. Productivity will customize an approach to build and integrate these capabilities in your organization. Our patient focused process improvement practices have been used in hospitals, clinics, insurance, and government sources to discover and remedy systemic causes resulting in measurable patientcare improvements. Productivity Healthcare For more information visit For complete details on all of Productivity s public events, consulting and training services, visit our website at or give us a call at (203) or (800)